Circuit breaker operating mechanism component monitoring system and associated method

ABSTRACT

A component monitoring system structured to monitor circuit breaker assembly operating mechanism component characteristics is provided. The component monitoring system includes a record assembly, at least one sensor assembly and a comparison assembly. The record assembly includes selected nominal data for a selected circuit breaker component. The least one sensor assembly is structured to measure a number of actual component characteristics of a selected circuit breaker component and to transmit actual component characteristic output data. The comparison assembly is structured to compare the sensor assembly actual component characteristic output data to the selected nominal data and to provide an indication of whether the sensor assembly output data is acceptable when compared to the selected nominal data. The at least one sensor assembly is in electronic communication with the comparison assembly.

BACKGROUND OF THE INVENTION

Field of the Invention

The disclosed and claimed concept relates to a circuit breaker with acomponent monitoring system and, more specifically, to circuit breakerwith a displaced component monitoring system.

Background Information

Circuit breaker assemblies provide protection for electrical systemsfrom electrical fault conditions such as current overloads, shortcircuits, and low level voltage conditions. Typically, circuit breakersinclude a trip device and an operating mechanism. The trip devicedetects an over-current condition and actuates the operating mechanism.The operating mechanism open and closes, either manually or in responseto the trip device, a number of electrical contacts. In an exemplaryembodiment, the operating mechanism utilizes a number of springs togenerate force for the opening and closing operations. Further, thesprings are maintained in a charged state so that, for example,following an over-current condition, the contacts may be closed withouthaving to charge the springs.

The components of the operating mechanism are subject to wear and tearover time. When an operating mechanism component becomes worn, theoperating mechanism component should be replaced. Rather than waitingfor an operating mechanism component to become worn to the point ofneeding replacement, it is desirable to replace the operating mechanismcomponent preemptively. That is, it is desirable to monitor the “health”of the operating mechanism components and diagnose when an operatingmechanism component will need replaced.

There is, therefore, a need for a component monitoring system structuredto monitor circuit breaker assembly operating mechanism componentcharacteristics. Further, there is a need for a component monitoringsystem structured to monitor a first circuit breaker assembly operatingmechanism component characteristic so as to determine if a secondcircuit breaker assembly operating mechanism component needsreplacement.

SUMMARY OF THE INVENTION

These needs, and others, are met by at least one embodiment of thedisclosed and claimed embodiments which provides for a componentmonitoring system structured to monitor circuit breaker assemblyoperating mechanism component characteristics. The component monitoringsystem includes a record assembly, at least one sensor assembly, and acomparison assembly. The record assembly includes selected nominal datafor a selected circuit breaker component. The least one sensor assemblyis structured to measure a number of actual component characteristics ofa selected circuit breaker component and to transmit actual componentcharacteristic output data. The comparison assembly is structured tocompare the sensor assembly actual component characteristic output datato the selected nominal data and to provide an indication of whether thesensor assembly output data is acceptable when compared to the selectednominal data. The at least one sensor assembly is in electroniccommunication with the comparison assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

A full understanding of the invention can be gained from the followingdescription of the preferred embodiments when read in conjunction withthe accompanying drawings in which:

FIG. 1 is an isometric view of a circuit breaker assembly.

FIG. 2 is a side view of a circuit breaker assembly.

FIG. 2A is a side view of a circuit breaker assembly.

FIG. 3 is a schematic view of a component monitoring system.

FIG. 4 is a partial side view of selected operating mechanism componentswith selected component characteristics.

FIG. 5 is a graph showing an envelope of current and charging time.

FIG. 6 is a graph showing a selected nominal time period of the chargingprocess.

FIG. 7 is a graph showing nominal and failure mode characteristics.

FIG. 8 is a flow chart of the disclosed method.

FIG. 9 is an isometric view of a monitoring latch assembly.

FIG. 10 is a side view of a monitoring latch assembly.

FIG. 11 is a top view of a monitoring latch assembly.

FIG. 12 is graph showing a relationship between the opening speed of themovable contact assembly and the contact spring force.

FIG. 13 is a graph showing a relationship between the latch force andthe contact spring force.

FIG. 14A is a first portion of a flow chart of the method associatedwith the stress sensor module, the control circuit monitoring module,the open/close evaluation module and the charging motor monitoringmodule.

FIG. 14B is a second portion of a flow chart of the method associatedwith the stress sensor module, the control circuit monitoring module,the open/close evaluation module and the charging motor monitoringmodule.

FIG. 15 is a flow chart showing the steps for vibration based diagnosisand prognosis.

FIG. 16 is a flow chart showing the steps for signal segmentation.

FIG. 17 is a graph of exemplary model selected nominal data for thevibrations associated with a masterpiece circuit breaker during aclosing operation.

FIG. 18A is a visual representation of a comparison of calculatedcomponent characteristics to model selected nominal data for a first andsecond sensor assembly for a first sensor. FIG. 18B is a visualrepresentation of a comparison of calculated component characteristicsto model selected nominal data for a first and second sensor assemblyfor a second sensor.

FIG. 19 is another visual representation of a comparison of calculatedcomponent characteristics to model selected nominal data.

FIG. 20 is a model to estimate displacement curve from vibration data.

FIG. 21 is a graph of exemplary model selected nominal vibration datawith a line representing estimated displacement.

FIG. 22 is a graph representing a Closing Displacement Characteristic.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

It will be appreciated that the specific elements illustrated in thefigures herein and described in the following specification are simplyexemplary embodiments of the disclosed concept, which are provided asnon-limiting examples solely for the purpose of illustration. Therefore,specific dimensions, orientations, assembly, number of components used,embodiment configurations and other physical characteristics related tothe embodiments disclosed herein are not to be considered limiting onthe scope of the disclosed concept.

Directional phrases used herein, such as, for example, clockwise,counterclockwise, left, right, top, bottom, upwards, downwards andderivatives thereof, relate to the orientation of the elements shown inthe drawings and are not limiting upon the claims unless expresslyrecited therein.

As used herein, the singular form of“a,” “an,” and “the” include pluralreferences unless the context clearly dictates otherwise.

As used herein, the statement that two or more parts or components are“coupled” shall mean that the parts are joined or operate togethereither directly or indirectly, i.e., through one or more intermediateparts or components, so long as a link occurs. As used herein, “directlycoupled” means that two elements are directly in contact with eachother. It is noted that moving parts, such as but not limited to circuitbreaker contacts, are “directly coupled” when in one position, e.g., theclosed, second position, but are not “directly coupled” when in theopen, first position. As used herein, “fixedly coupled” or “fixed” meansthat two components are coupled so as to move as one while maintaining aconstant orientation relative to each other. Accordingly, when twoelements are coupled, all portions of those elements are coupled. Adescription, however, of a specific portion of a first element beingcoupled to a second element, e.g., an axle first end being coupled to afirst wheel, means that the specific portion of the first element isdisposed closer to the second element than the other portions thereof.

As used herein, the phrase “removably coupled” means that one componentis coupled with another component in an essentially temporary manner.That is, the two components are coupled in such a way that the joiningor separation of the components is easy and would not damage thecomponents. For example, two components secured to each other with alimited number of readily accessible fasteners are “removably coupled”whereas two components that are welded together or joined by difficultto access fasteners are not “removably coupled.” A “difficult to accessfastener” is one that requires the removal of one or more othercomponents prior to accessing the fastener wherein the “other component”is not an access device such as, but not limited to, a door.

As used herein, “operatively coupled” means that a number of elements orassemblies, each of which is movable between a first position and asecond position, or a first configuration and a second configuration,are coupled so that as the first element moves from oneposition/configuration to the other, the second element moves betweenpositions/configurations as well. It is noted that a first element maybe “operatively coupled” to another without the opposite being true.

As used herein, “characteristics” of elements or assemblies include, butare not limited to, the position of the elements or assemblies, distancemoved by one or more of the elements or assemblies, the force generatedwithin or between one or more of the elements or assemblies, or stresswithin one or more of the elements or assemblies. The measurablecharacteristic motion may be linear, angular (in 2D or 3D references)and may be convertible to another type of motion with appropriatecalibration (factory or field set). The characteristic can be convertedinto another form (such as, but not limited to, electrical energy,electromechanical energy/force, magnetic, thermal, etc.).

As used herein, a “coupling assembly” includes two or more couplings orcoupling components. The components of a coupling or coupling assemblyare generally not part of the same element or other component. As such,the components of a “coupling assembly” may not be described at the sametime in the following description.

As used herein, a “coupling” or “coupling component(s)” is one or morecomponent(s) of a coupling assembly. That is, a coupling assemblyincludes at least two components that are structured to be coupledtogether. It is understood that the components of a coupling assemblyare compatible with each other. For example, in a coupling assembly, ifone coupling component is a snap socket, the other coupling component isa snap plug, or, if one coupling component is a bolt, then the othercoupling component is a nut.

As used herein, a “fastener” is a separate component structured tocouple two or more elements. Thus, for example, a bolt is a “fastener”but a tongue-and-groove coupling is not a “fastener.” That is, thetongue-and-groove elements are part of the elements being coupled andare not a separate component.

As used herein, “correspond” indicates that two structural componentsare sized and shaped to be similar to each other and may be coupled witha minimum amount of friction. Thus, an opening which “corresponds” to amember is sized slightly larger than the member so that the member maypass through the opening with a minimum amount of friction. Thisdefinition is modified if the two components are to fit “snugly”together. In that situation, the difference between the size of thecomponents is even smaller whereby the amount of friction increases. Ifthe element defining the opening and/or the component inserted into theopening are made from a deformable or compressible material, the openingmay even be slightly smaller than the component being inserted into theopening. With regard to surfaces, shapes, and lines, two, or more,“corresponding” surfaces, shapes, or lines have generally the same size,shape, and contours.

As used herein, a “computer” is a device structured to process datahaving at least one input device, e.g. a keyboard, mouse, ortouch-screen, at least one output device, e.g. a display, a graphicscard, a communication device, e.g. an Ethernet card or wirelesscommunication device, permanent memory, e.g. a hard drive, temporarymemory, i.e. random access memory, and a processor, e.g. a programmablelogic circuit. The “computer” may be a traditional desktop unit but alsoincludes cellular telephones, tablet computers, laptop computers, aswell as other devices, such as gaming devices that have been adapted toinclude components such as, but not limited to, those identified above.Further, the “computer” may include components that are physically indifferent locations. For example, a desktop unit may utilize a remotehard drive for storage. Such physically separate elements are, as usedherein, a “computer.”

As used herein, the word “display” means a device structured to presenta visible image. Further, as used herein, “present” means to create animage on a display which may be seen by a user.

As used herein, a “computer readable medium” includes, but is notlimited to, hard drives, CDs, DVDs, magnetic tape, floppy drives, andrandom access memory.

As used herein, “permanent memory” means a computer readable storagemedium and, more specifically, a computer readable storage mediumstructured to record information in a non-transitory manner. Thus,“permanent memory” is limited to non-transitory tangible media.

As used herein, “stored in the permanent memory” means that a module ofexecutable code, or other data, has become functionally and structurallyintegrated into the storage medium.

As used herein, a “file” is an electronic storage construct forcontaining executable code that is processed, or, data that may beexpressed as text, images, audio, video or any combination thereof.

As used herein, a “module” is an electronic construct used by acomputer, or other processing assembly, and includes, but is not limitedto, a computer file or a group of interacting computer files such as anexecutable code file and data storage files, used by a processor andstored on a computer readable medium. Modules may also include a numberof other modules. It is understood that modules may be identified bytheir purpose of function. Unless noted otherwise, each “module” isstored in permanent memory of at least one computer or processingassembly. All modules are shown schematically in the Figures.

As used herein, and in the phrase “[x] moves between a first positionand a second position corresponding to [y] first and second positions,”wherein “[x]” and “[y]” are elements or assemblies, the word“correspond” means that when element [x] is in the first position,element [y] is in the first position, and, when element [x] is in thesecond position, element [y] is in the second position. It is noted that“correspond” relates to the final positions and does not mean theelements must move at the same rate or simultaneously. That is, forexample, a hubcap and the wheel to which it is attached rotate in acorresponding manner. Conversely, a spring biased latched member and alatch release move at different rates. That is, as an example, a latchrelease moves between a first position, wherein the latched member isnot released, and a second position, wherein the latched member isreleased. The spring-biased latched member moves between a first latchedposition and a second released position. The latch release may moveslowly between positions and, until the release is in the secondposition, the latched member remains in the first position. But, as soonas the latch release reaches the second position, the latched member isreleased and quickly moves to the second position. Thus, as statedabove, “corresponding” positions mean that the elements are in theidentified first positions at the same time, and, in the identifiedsecond positions at the same time.

As used herein, the statement that two or more parts or components“engage” one another shall mean that the elements exert a force or biasagainst one another either directly or through one or more intermediateelements or components. Further, as used herein with regard to movingparts, a moving part may “engage” another element during the motion fromone position to another and/or may “engage” another element once in thedescribed position. Thus, it is understood that the statements, “whenelement A moves to element A first position, element A engages elementB,” and “when element A is in element A first position, element Aengages element B” are equivalent statements and mean that element Aeither engages element B while moving to element A first position and/orelement A either engages element B while in element A first position.

As used herein, “operatively engage” means “engage and move.” That is,“operatively engage” when used in relation to a first component that isstructured to move a movable or rotatable second component means thatthe first component applies a force sufficient to cause the secondcomponent to move. For example, a screwdriver may be placed into contactwith a screw. When no force is applied to the screwdriver, thescrewdriver is merely “coupled” to the screw. If an axial force isapplied to the screwdriver, the screwdriver is pressed against the screwand “engages” the screw. However, when a rotational force is applied tothe screwdriver, the screwdriver “operatively engages” the screw andcauses the screw to rotate.

As used herein, the word “unitary” means a component that is created asa single piece or unit. That is, a component that includes pieces thatare created separately and then coupled together as a unit is not a“unitary” component or body.

As used herein, the term “number” shall mean one or an integer greaterthan one (i.e., a plurality).

As used herein, “associated” means that the elements are part of thesame assembly and/or operate together, or, act upon/with each other insome manner. For example, an automobile has four tires and four hubcaps. While all the elements are coupled as part of the automobile, itis understood that each hubcap is “associated” with a specific tire.

As used herein, in the phrase “[x] moves between its first position andsecond position,” or, “[y] is structured to move [x] between its firstposition and second position,” “[x]” is the name of an element orassembly. Further, when [x] is an element or assembly that moves betweena number of positions, the pronoun “its” means “[x],” i.e. the namedelement or assembly that precedes the pronoun “its.”

As used herein, “in electronic communication” is used in reference tocommunicating a signal via an electromagnetic wave or signal. “Inelectronic communication” includes both hardline and wireless forms ofcommunication; thus, for example, a “data transfer” or “communicationmethod” via a component “in electronic communication” with anothercomponent means that data is transferred from one computer to anothercomputer (or from one processing assembly to another processingassembly) by physical connections such as USB, Ethernet connections orremotely such as NFC, blue tooth etc. and should not be limited to anyspecific device.

As used herein, “in electric communication” means that a current passes,or can pass, between the identified elements. Being “in electriccommunication” is further dependent upon an element's position orconfiguration. For example, in a circuit breaker, a movable contact is“in electric communication” with the fixed contact when the contacts arein a closed position. The same movable contact is not “in electriccommunication” with the fixed contact when the contacts are in the openposition.

A circuit breaker assembly 10 is shown, in part schematically, in FIGS.1 and 2. The circuit breaker assembly 10 includes a housing assembly 12,a conductor assembly 14, an operating mechanism 16, and a trip assembly18 (some elements shown schematically). The conductor assembly 14includes a number of conductive members, discussed below, which are inelectrical communication with a line and a load, not shown. In anexemplary embodiment, any “conductive” element is made from a conductivemetal such as, but not limited to, copper, aluminum, gold, silver, orplatinum. The conductor assembly 14 includes a movable contact assembly20 and a fixed contact assembly 22. The operating mechanism 16 isoperatively coupled to the movable contact assembly 20 and is structuredto move the movable contact assembly 20 between an open, first position,wherein the movable contact assembly 20 is effectively spaced from thefixed contact assembly 22, and a closed, second position, wherein themovable contact assembly 20 is coupled to, and in electricalcommunication with, the fixed contact assembly 22.

The operating mechanism 16 includes a number of components 28 each ofwhich has a number of characteristics. In an exemplary embodiment, theoperating mechanism components 28 include, but are not limited to, acharging motor assembly 30, number of cam members 32, a number ofsprings 34, a number of cam followers 36, a number of shafts 38, anumber of link members 40, a number of D-shafts 42, and a number oflatch members 44. It is understood that FIG. 2 is a schematic viewshowing a limited number of operating mechanism components 28. Forexample, as is known and in an exemplary embodiment, a circuit breakerassembly 10 includes a number of poles, such as but not limited to threepoles. Further, there is a movable contact assembly 20 and a fixedcontact assembly 22 associated with each pole. Further, it is understoodthat each movable contact assembly 20 is coupled to a contact spring 94(Shown schematically), discussed below. It is understood that thecontact spring 94 may be disposed within a housing assembly disposedabout the movable contact assembly 20. Generally, the operatingmechanism 16 moves through a number of configurations, e.g. open, close,trip (contact assembly 20 open and closing spring discharged andthereafter charged), and reset, however, for the purpose of thisdisclosure the operating mechanism 16 shall be identified as being ineither an open, first configuration, or a closed, second configuration;the operating mechanism 16 configurations correspond to the position ofthe movable contact assembly 20. That is, when the movable contactassembly 20 is in the first position, the operating mechanism 16 is inthe first configuration, and, when the movable contact assembly 20 is inthe second position, the operating mechanism 16 is in the secondconfiguration.

In an exemplary embodiment, the operating mechanism components 28 areoperatively coupled together. Further, the operating mechanismcomponents 28 are operatively coupled to the trip assembly 18. In thisconfiguration, the operating mechanism 16 is structured to move themovable contact assembly 20 between the first position and secondposition, as noted above. Further, the operating mechanism 16 isstructured to move the movable contact assembly 20 from the secondposition to the first position in response to an overcurrent conditiondetected by the trip assembly 18. In an exemplary embodiment, the numberof springs 34 are structured to cause a rapid movement of the movablecontact assembly 20 between positions. That is, generally, a spring 34is compressed prior to moving the movable contact assembly 20 and, whenthe movable contact assembly 20 is to be moved, the spring 34 isreleased causing a rapid movement of the movable contact assembly 20.

The charging motor assembly 30, shown schematically, is, in an exemplaryembodiment, an electric motor. The charging motor assembly 30 is coupledto the housing assembly 12. The charging motor assembly 30 includes arotating output shaft 50. In an exemplary embodiment, the charging motorassembly 30 includes an AC conductor 46, an AC/DC converter 47, and a DCmotor 48. The output shaft 50 is, in an exemplary embodiment, part ofthe DC motor 48. The AC conductor 46 is coupled to, and in electricalcommunication with, an AC line (not shown) as well as the AC/DCconverter 47. The AC/DC converter 47 is coupled to, and in electricalcommunication with, the DC motor 48. In this configuration, currentpasses through the AC conductor 46 and the AC/DC converter 47 during theactuation of the DC motor 48.

The number of shafts 38 includes a cam drive shaft 52 a rocker linkshaft 54, a lay shaft 56, a close latch shaft 58 and a trip latch shaft59. It is understood, and shown schematically, that each shaft 38 iseither rotatably coupled to the housing assembly 12 or fixed to thehousing assembly 12 (shown in FIG. 1). Thus, it is understood that arotating shaft 38 rotates about a longitudinal axis of rotation.Conversely, components 28 may rotate about a fixed shaft 38. Thecharging motor assembly output shaft 50 is operatively coupled to thecam drive shaft 52. As such, actuation of the charging motor assembly 30causes the cam drive shaft 52 to rotate. As described below, the rockerlink shaft 54 is coupled, directly coupled or fixed to a number ofrocker link members 70.

The number of cam members 32 includes a first charging cam 60. The firstcharging cam 60 is coupled, directly coupled or fixed to the cam driveshaft 52 in a fixed orientation. Thus, the first charging cam 60 and thecam drive shaft 52 rotate with each other. That is, actuation of thecharging motor assembly 30 causes the first charging cam 60 to rotate.Further, various spring 34 forces, acting through various link members40, cause the first charging cam 60, and therefore the cam drive shaft52, to rotate. Rotation of the cam drive shaft 52 does not cause thecharging motor assembly output shaft 50 to rotate.

The number of link members 40 includes, but is not limited to, a rockerlink member 70, a first link member 74, a lay shaft casting link member76, a main link coupler member 77, a main link member 78, and a closelatch link member 80. Generally, each link member 40 includes anelongated body with a first end and a second end, which will beidentified by reference numbers as needed below. A rotational coupling,which will be identified by reference numbers as needed below, isdisposed at each link end. A rotational coupling may be any couplingthat allows rotation such as, but not limited to an opening in each linkend with a pin through both link end openings.

The number of springs 34 includes a closing spring 90, an opening spring92, and a contact spring 94. Generally, each spring 34 includes a bodywith a first end and a second end, which will be identified by referencenumbers as needed below. In an exemplary embodiment, each spring 34 is acompression spring. As noted above, the schematic side view of FIGS. 2,2A shows a single closing spring 90, opening spring 92, and contactspring 94; it is understood that there may be, and typically are, anumber of each named spring 90, 92, 94. Each closing spring 90 ischarged, i.e. compressed, prior to moving the movable contact assembly20 from the first position to the second position. That is, each closingspring 90 is charged and the energy is released to rapidly move themovable contact assembly 20 from the first position to the secondposition. Each opening spring 92 is charged, i.e. compressed, prior tomoving the movable contact assembly 20 from the second position to thefirst position. That is, each opening spring 92 is charged and theenergy is released to rapidly move the movable contact assembly 20 fromthe second position to the first position. The closing springs 90 andthe opening springs 92 may be charged at any time prior to theassociated movement of the movable contact assembly 20. That is, forexample, the opening springs 92 are charged as soon as the movablecontact assembly 20 moves to the second position and are maintained inthe charged state in the event of an overcurrent condition at a latertime. Similarly, the closing springs 90 are charged as soon as themovable contact assembly 20 moves to the second position so that,following an overcurrent condition and subsequent opening of the contactassemblies 20, 22, the movable contact assembly 20 can be returned tothe second position. The contact spring 94 is structured to bias themovable contact assembly 20 toward the fixed contact assembly 22 whenthe movable contact assembly 20 is in the second position. Thus, duringnormal operation, i.e. when the movable contact assembly 20 is in theclosed, second position and in an exemplary embodiment, the closingspring 90, the opening spring 92, and the contact spring 94 are eachcharged. Thus, the spring forces, also identified as reactive springforces, act upon any other operating mechanism components 28 that areoperatively coupled to the springs 34.

The number of cam followers 36 includes a closing spring cam follower120 and a main roller 122. It is understood that a cam follower 36operatively engages a cam member 32, is operatively engaged by a cammember 32, or both. A cam follower 36, in an exemplary embodiment, is awheel-like roller structured to engage the outer surface of a cam member32. That is, in an exemplary embodiment, a cam member 32 is a generallyplanar, disk-like body 37 including a spiral radial surface 39 with anoffset 41, i.e. a generally radial step. A cam follower 36 travels over,and engages the cam member body radial surface 39. Thus, because the cammember body radial surface 39 is not a constant distance from the centerof the cam member body 37, which is the axis of rotation, the camfollower 36 moves closer or further from the center of the cam memberbody 37.

The number of D-shafts 42 includes a trip latch D-shaft 124 and a closelatch D-shaft 126. Each D-shaft 42 is rotatably coupled to the housingassembly 12. Each D-shaft 42 operatively engages, and/or is operativelyengaged by, a latch member 44. The latch members 44 are discussed indetail below. Generally, however, a latch member 44 is movable andincludes a latching surface, discussed below, that is disposed adjacentto a D-shaft 42. When the D-shaft is in a first orientation, the curvedportion of the D-shaft surface is disposed in the path of travel of thelatch member latching surface. When the D-shaft 42 rotates to a secondorientation, wherein the flat portion of the D-shaft surface is disposedadjacent the latch member 44, the D-shaft surface is not disposed in thepath of travel of the latch member engagement surface. Thus, in oneorientation, the D-shaft 42 blocks the travel of the latch member 44.This is the latched orientation of the D-shaft 42 wherein the associatedlatch member 44 is latched. In the other orientation, the D-shaft 42does not block the travel of the latch member 44. This is the unlatchedorientation of the D-shaft 42 wherein the associated latch member 44 isunlatched.

In an exemplary embodiment, the identified operating mechanismcomponents 28 are assembled as follows. A contact spring first end 130,shown schematically, is coupled, directly coupled, or fixed to themovable contact assembly 20. A contact spring second end 132 is coupled,directly coupled, or rotatably coupled to a rocker link member first end134. A rocker link member medial portion 136 is coupled, directlycoupled, or fixed to rocker link shaft 54. Further, the rocker linkmember 70 includes an opening spring mounting 137 disposed between therocker link member medial portion 136 and a rocker link member secondend 138. An opening spring first end 139 is coupled, directly coupled,or fixed to the rocker link member opening spring mounting 137.

In an exemplary embodiment, the rocker link shaft 54 is rotatablycoupled to the housing assembly 12 and the rocker link member 70 isfixed to the rocker link shaft 54. The rocker link member second end 138is coupled, directly coupled, or rotatably coupled to a first link firstend 140. A first link second end 142 is coupled, directly coupled, orrotatably coupled to a lay shaft casting link member first end 144. Anoffset lay shaft casting link member medial portion 146 is rotatablycoupled to the lay shaft 56. The lay shaft 56 is coupled, directlycoupled, or fixed to the housing assembly 12. A lay shaft casting linkmember second end 148 is coupled, directly coupled, or rotatably coupledto a main link coupler member first end 150. A main link coupler membersecond end 152 is coupled, directly coupled, or rotatably coupled to amain link member first end 154. Further, the main roller 122 isrotatably coupled to a rotational coupling at the interface of the mainlink coupler member second end 152 and the main link member first end154. A main link member second end 156 is coupled, directly coupled, orrotatably coupled to a trip latch member body latching first end 184(FIG. 9), discussed below.

Further, the first charging cam 60 is fixed to the cam drive shaft 52,as described above. The first charging cam 60 is disposed adjacent tothe main roller 122. That is, the first charging cam 60 is disposed sothat the main roller 122 operatively engages the first charging cammember body radial surface 39. A close latch member 170, discussedbelow, is disposed adjacent to the first charging cam 60. In anexemplary embodiment, the close latch member 170 is rotatably coupled tothe close latch shaft 58. The close latch shaft 58 is coupled, directlycoupled, or fixed to the housing assembly 12. A close latch link memberfirst end 160 is coupled, directly coupled, or rotatably coupled to aclose latch member first end 171, discussed below. A close latch linkmember second end 162 is rotatably coupled to the close latch follower123.

The configuration described above is an exemplary embodiment of anoperating mechanism 16 that is structured to move the movable contactassembly 20 between an open, first position, wherein the movable contactassembly 20 is effectively spaced from the fixed contact assembly 22,and a closed, second position, wherein the movable contact assembly 20is coupled to, and in electrical communication with, the fixed contactassembly 22. Movement of the movable contact assembly 20 may beintentionally initiated or be in response to an overcurrent condition,i.e. initiated by the trip assembly 18.

The circuit breaker assembly 10, and in an exemplary embodiment theoperating mechanism 16, includes a component monitoring system 200structured to monitor a number of circuit breaker assembly components'characteristics including those of operating mechanism 16 as exemplifiedabove. In an exemplary embodiment, the component monitoring system 200is a displaced component monitoring system 201. As used herein, a“displaced component monitoring system” 201 means a system wherein afirst component is monitored so as to diagnose a characteristic of adifferent, second component. Three exemplary embodiments of thecomponent monitoring system 200, which are also displaced componentmonitoring systems 201, are discussed below. Generally, a componentmonitoring system 200 is structured to measure a componentcharacteristic, such as, but not limited to, the force generated by acharged spring 34 while in the second configuration. Further, thecomponent monitoring system 200 compares the measured componentcharacteristic to a selected nominal component characteristic. The“selected nominal” component characteristic data, alternatively“selected nominal data,” as used herein, are determined via use, testingor determined theoretically and is utilized as a standard templateagainst which the acquired data is compared. The “selected nominal data”may be defined specifically, as a range, or as a coefficient.

For example, each mechanism motion and its characteristics are governedby selected mathematical equations associated with the specific physicalform of the components. These equations may be linear or nonlinear,partial or ordinary derivative in nature. The equations correlate thedependent variables (such as but not limited to, contact wear, contactmoving speed, forces, and displacements etc.) and some independentvariables (such as, but not limited to, linages ratio, linkage length,spring characteristics e.g. length, spring constant etc.). Suchequations may take a generalized form, such as, but not limited to:y ₁=β₁ f ₁(t ₁)+β₂ f ₂(t ₂)+β₃ f ₃(t ₃)+ . . . +β_(k) f _(k)(t _(k))+ .. . +ε. Or,y ₁=β₁ f ₁(t ₁ ,t ₂ ,t ₃ , . . . t _(n))+β₂ f ₂(t ₁ ,t ₂ ,t ₃ , . . . t_(n))+ . . . +ε. Or,y ₁=β₁ f′ ₁(t ₁ ,t ₂ ,t ₃ , . . . t _(n))+β₂ f′ ₂(t ₁ ,t ₂ ,t ₃ , . . .t _(n))+ . . . +ε.

The multipliers (β_(n)), associated with directly or indirectlyindependent variables (f_(n)(t_(n)) or f_(n)(t₁, t₂, t₃, . . . t_(n)) orf′_(n)(t₁, t₂, t₃, . . . t_(n))) are, as used herein, “coefficients.” Adetailed example is provided below. The right side of the equation canbe identified as the “physics of operation” of the system whereas theleft side of the equation can be identified as a “physically expecteddependent variable.” The difference between the left side of theequation and right side of the equation are due to experimental errorsor unknown factors in practice etc., can be associated to E or the errorterm.

Further, as used herein “selected nominal data” may be associated withany component characteristic. Alternatively, a specific componentcharacteristic, and nominal data associated therewith, may be identifiedby a specific name. For example if the relevant component characteristicis the “correlation coefficient” (discussed below), then the “selectednominal data” for that component characteristic is identified as“selected nominal correlation coefficient” data. Further, data acquiredor collected during use of a circuit breaker assembly 10 is, as usedherein, “acquired selected nominal data.” Further, data acquired orcollected during use of the circuit breaker assembly 10 to which thecomponent monitoring system 200 is coupled is, as used herein, “acquiredlocal selected nominal data.”

As shown in FIG. 3, the component monitoring system 200 includes arecord assembly 210, at least one sensor assembly 220, or a number ofsensor assemblies 220, a comparison assembly 230, and an output assembly240. The record assembly 210 is, in an exemplary embodiment, a databasemodule 212 stored in a memory assembly 214 and/or permanent memoryassembly 215. As used herein, the memory assembly 214 and/or permanentmemory assembly 215 include any electrical memory device such as, butnot limited to, a magnetic drive, flash memory, or an optical drive, butdoes exclude transitory media. The record assembly 210, and in anexemplary embodiment the database module 212, includes data representingselected nominal data of a number of selected operating mechanismcomponents 28.

Further, the database module 212 is structured to be updated. That is,the selected nominal data may be replaced or amended, e.g., additionaldata may be added to the selected nominal data. Updating the selectednominal data, in an exemplary embodiment, occurs following a failure ofan operating mechanism component 28.

For example, it is understood that as the condition of closing spring 90deteriorates, the closing spring 90 becomes more stiff causing a changein the spring constant of the closing spring 90. Thus, the selectednominal data, in an exemplary embodiment, includes data representing aminimum closing time for the closing spring 90 as well as a rangeindicating the acceptable stress on closing spring 90 when the movablecontact assembly 20 is in the second position. Upon failure of theclosing spring 90, e.g. a failure to close within the minimum closingtime, the last recorded stress on the closing spring 90 is added to theselected nominal data associated with the closing spring 90. Such newdata is “acquired local selected nominal data,” as discussed above. Suchacquired local selected nominal data is subsequently used by thecomparison assembly 230, as discussed below. Alternatively, the new datamay be copied to other component monitoring systems 200 in other circuitbreaker assemblies; in this instance, the data is “acquired selectednominal data.” It is understood that by updating the selected nominaldata the component monitoring system 200 improves its predictions ofremaining useful life (RUL), as discussed below. Stated alternately, thecomponent monitoring system 200 learns new operating mechanism component28 characteristics that indicate failure.

Further, in an exemplary embodiment, the selected nominal data is storedin a “reduced data set.” As used herein, a “reduced data set” means thatthe amount of data stored is limited to a set of between two and fivenumbers, i.e. 20-40 bytes per sensor assembly 220. For example, if theselected nominal data is “coefficient data,” then the coefficients canbe stored directly or indirectly by associating them with some form ofstatistical distribution function e.g.β_(n) ˜N(β_(n) ^(average),β_(n) ^(variance)) or β_(n) ˜W(β_(n)^(scale),β_(n) ^(shape),

where, N represents normal distribution and W represents Weibulldistribution functions and the stored parameters would be either β_(n)and/or (β_(n) ^(average),β_(n) ^(variance)).

The record assembly 210 is, in an exemplary embodiment, also inelectronic communication with the output assembly 240. For example, ifthe output assembly 240 includes a display 244, the record assembly 210is in electronic communication with the display 244 and is structured topresent data on the display 244. As discussed below, the comparisonassembly 230 is also in electronic communication with the display 244and is structured to present actual component characteristics. Thus, auser, in an exemplary embodiment, can visually compare the actualcomponent characteristics to the selected nominal data. For example, theselected nominal data may be in the form of an acceptable range. Thisrange may be presented on the display 244. The actual componentcharacteristic may be presented as a data point relative to that range.Thus, a user can see if the actual component characteristic is withinthe acceptable range or not, and how close the actual componentcharacteristic is to being outside the acceptable range. In anotherexemplary embodiment, not shown, the selected nominal data is printed ona transparent film and is mounted on a display 244. The selected nominaldata may be presented or shown in other manners as well.

In an exemplary embodiment, each sensor assembly 220 includes, or isstructured to be coupled to and in electronic communication with, apower source (not shown). The power source may be disposed within eachsensor assembly 220. Further, each sensor assembly 220 is structured tomeasure a number of “actual component characteristics,” as definedbelow, of a sub-assembly of the circuit breaker assembly 10, such as,but not limited to a selected operating mechanism component 28.Alternatively, a sensor assembly 220 is structured to measure a numberof actual component characteristics of a number of circuit breakerassembly sub-assemblies, a substantial portion of the circuit breakerassembly 10, or, the entire circuit breaker assembly 10, as discussedbelow. The component characteristics that are physically measured, suchas, but not limited to, deformation of the sub-assembly of the circuitbreaker assembly 10, such as, but not limited to a selected operatingmechanism component 28 are the “measured component characteristics” asused herein. Further, a sub-assembly of the circuit breaker assembly 10,such as, but not limited to a selected operating mechanism component 28may be associated with more than one sensor assembly 220. Generallyhereinafter, however, as an initial example and for simplicity, it isassumed that there is a single sensor assembly 220 structured to measurea single actual component characteristic. The sensor assembly 220 isfurther structured to transmit output data representing the selectedcircuit breaker component's actual component characteristic. In thisexemplary embodiment, the output data is an electronic construct suchas, but not limited to, a signal. Hereinafter, the “output datarepresenting the selected circuit breaker component's actual componentcharacteristic” is identified as “actual component characteristic outputdata.” In an exemplary embodiment, the actual component characteristicoutput data signal has characteristics of between about 0-10V DC,between about 4-20 mA and between about 100-1000 Hz, or, digital signaloutput. As stated, this is an example and is not limiting.

The comparison assembly 230 includes a processing assembly 232, aninput/output device 234, and a comparison module 236. The processingassembly 232 includes a programmable logic circuit, memory, and aninfrastructure, such as, but not limited to a printed circuit board(none shown). As used herein, a “processing assembly” is not a generalpurpose computer. The processing assembly 232 is structured to executethe comparison module 236. The comparison module 236, when executed, isstructured to acquire the selected nominal data for the selectedcomponent from the record assembly 210 and to record “actual componentcharacteristics.” That is, as used herein, “actual componentcharacteristics” means the measured component characteristics (in anexemplary embodiment, represented by the actual component characteristicoutput data) and/or “calculated component characteristics.” “Calculatedcomponent characteristics” means component characteristics based onmeasured component characteristics and equations such as, but notlimited to, the equations set forth below.

In an exemplary embodiment, the comparison assembly 230, and in anexemplary embodiment the comparison module 236, is structured to executethe calculations used to determine the “calculated componentcharacteristics.” It is understood, however, that although the“calculated component characteristics” are determined by the comparisonassembly 230, the “calculated component characteristics” are based uponmeasured component characteristics; thus, the “calculated componentcharacteristics” are fixed upon the measurement of the measuredcomponent characteristics by the sensor assembly 220. Accordingly, asused herein, the “calculated component characteristics” may also beassociated with the sensor assembly 220 and may be generated by thesensor assembly 220. In an alternative embodiment, the sensor assembly220 includes a sensor module 222 that is structured to perform thecalculation needed to generate “calculated component characteristics.”

The comparison assembly 230, and in an exemplary embodiment thecomparison module 236, is in electronic communication with the recordassembly 210 and is structured to access the selected nominal datawithin the record assembly 210. The comparison assembly 230, and in anexemplary embodiment the comparison module 236, is further structured tocompare the actual component characteristics and the selected nominaldata and to communicate a signal to an output device 242, discussedbelow. For example, the comparison assembly 230, and in an exemplaryembodiment the comparison module 236, is structured to compare theactual component characteristics and the selected nominal data so as todetermine the remaining useful life for a selected circuit breakercomponent 28 and to provide an indication signal representing anindication of remaining useful life for a selected operating mechanismcomponent 28. The indication of remaining useful life is, in anexemplary embodiment, calculated according to the equation which maytake the generalized linear or non-linear format given below, but notlimited to the following, identified as Equation A:y=Tβ+εory ₁=β₁ f ₁(t ₁)+β₂ f ₂(t ₂)+β₃ f ₃(t ₃)+ . . . +β_(k) f _(k)(t _(k))+ε₁ory ₁=β₁ f ₁(x ₁)+β₂ f ₂(x ₂)+β₃ f ₃(x ₃)+ . . . +β_(k) f _(k)(x_(k))+ε₁  Equation Awherein:y=Single column vector containing raw data acquired at certain times(size: n×1) e.g., sensor monitored/derived signal of temperature, gaspressure, event timing/duration data timings etc. or, in general, anydependent variable that may or may not be measured directly but used togauge the system health.T=Design matrix that assigns a proper relation between dependent andindependent variables (size: n×k) e.g., time function or forms offunctions containing time (t)ε(f₁(t₁), f₂(t₂), . . . , f_(k)(t_(k))).X=Design matrix that assigns a proper relation between dependent andindependent variables (size: n×k)ε(f₁(x₁), f₂(x₂), . . . , f_(k)(x_(k)))where, x_(i) represents the measurable or independent variable.β=Vector with k parameters forming model equation=[β₁β₂ . . .β_(k)]^(T), etc. are the basic functions (can take any form but finallymay be fitted to the polynomial form and which vary relative to theselected component 22).ε˜N(O,σ²)=independent and identically distributed random variable(iid)ε(ε₁, ε₂, ε₃, . . . , ε_(n)).

In an exemplary embodiment, and as a specific example, a robustpolynomial model selection is used to determine the physics of failureof a transient natural convection cooled heat sink, installed on theconductor arm of the circuit breaker, and can be considered as anoperating mechanism component 28. In this exemplary embodiment,temperature sensors (mounted on the conductor arms and inside thecircuit breaker cabinet), velocity sensor (mounted inside the circuitbreaker cabinet) are installed. The 1D problem may be defined from theprinciples of heat transfer by the equation:

${{T(t)} - T_{\infty}} = {\frac{b}{a} + {( {T_{i} - T_{\infty} - \frac{b}{a}} ){\exp( {- {at}} )}}}$wherein:

T(t)=Temperature of the system at any given time (t in sec);

T_(i)=Initial temperature of the system (° C.);

T_(∞)=Ambient temperature (° C.); and

a and b constants determined by material properties, heat source andother transient heat transfer model constants and a priori known fromthe experiments in the laboratory. Further substitutions andmodifications may give:

$y_{1} = {{{\beta_{0}X^{0}} + {\beta_{1}X^{1}} + {ɛ_{i}\mspace{14mu}{with}\mspace{14mu}\beta_{0}}} = {{\frac{b}{a}\mspace{14mu}{and}\mspace{14mu}\beta_{1}} = ( {T_{i} - T_{\infty} - \frac{b}{a}} )}}$where, X=exp(−αt) and y=T(t)−T_(∞).The above equation is similar to the generalized linear form presentedin equation A, above.

As another exemplary embodiment, and as a specific example, thetemperature rise on the conductor arm of the circuit breaker is directlyproportional to the square of current passing through that conductor,and directly proportional to the ambient/surrounding temperature andinversely related to the air convection around the conductor (based onforced connection heat transfer principles). Thus, an equation can bemodeled as:

T ∝ I²; T ∝ T_(∞); and  T ∝ 1/u;$T = {a + {b \times I^{2}} + {c \times T_{\infty}} + {\frac{d}{u}.}}$With substitutions: β₀=α; β₁=b; β₂=c; and β₃=d, this equation againresembles the form of Equation A, above,wherein:

T=Temperature of the system at any given instant;

l=Electric current in amperes;

T_(∞)=Ambient temperature (° C.); and

u=Air velocity around the conductor (in m/s).

In an exemplary embodiment, the comparison module 236 includes a stresssensor module 236A, a control circuit monitoring module 236B, anopen/close evaluation module 236C and a charging motor monitoring module236D. These modules 236A, 236B, 236C, 236D operate according to themethod shown in FIGS. 14A and 14B.

The comparison assembly 230, and in an exemplary embodiment thecomparison module 236, is structured to determine if the actualcomponent characteristics are the result of sensor assembly 220 error.That is, it is known that sensor assemblies 220 may produce an erroneousresult that does not reflect the actual component characteristics. Theseerrors typically result in an unreasonable measurement and provide falsepositive alarm or false negative reading. The comparison module 236 isstructured to identify such error by including, i.e. recording in adatabase, a limited acceptable range for each actual componentcharacteristic. Any actual component characteristic that is measuredbeyond the limited acceptable range is ignored by the comparison module236. The limited acceptable range for each actual componentcharacteristic may be recorded in the database module 212.

The comparison assembly 230, and in an exemplary embodiment thecomparison module 236, is further structured to provide an indication ofthe acceptability of the actual component characteristics when comparedto the selected nominal data. That is, as used herein, “provide anindication of the acceptability of the actual component characteristicswhen compared to the selected nominal data” means that the comparisonassembly 230 makes a determination relating to the acceptability orreliability of an operating mechanism component 28. For example, thedetermination, in an exemplary embodiment, relates to one of thereliability of the machine or system, the remaining useful life, theexpected failure date or time to failure, or the confidence intervals ofthe above mentioned parameters. The indication may also be in the formof a binary selection, i.e. good or bad, yes or no, or in the form of acommunication, i.e. “charging spring needs replaced.”

The comparison module 236, when executed, is further structured togenerate an output signal. The output signal, in an exemplaryembodiment, represents indication of the acceptability of the actualcomponent characteristics when compared to the selected nominal data. Inan exemplary embodiment, the indication is in the form of an indicationof remaining useful life. In an exemplary embodiment, some failure modesdo not effect a singular component characteristic. Therefore, it ispossible that multiple monitoring modules 236A-D can detect the possiblefailure mode. Mapping a relationship between the pre-trained failuremode vs. monitoring module indication can be created based on thephysical circuit breaker working mechanism as well as the realmeasurement. The real measurement converted into the indication then canbe compared to the mapping relationship.

The comparison assembly input/output device 234 is in electroniccommunication with the record assembly 210, the processing assembly 232as well as all sensor assemblies 220. Thus, the comparison assemblyinput/output device 234 allows for communication between these elements.Further, the comparison assembly input/output device 234 is inelectronic communication with the output assembly 240.

The output assembly 240 includes an output device 242, such as, but notlimited to a display 244. The output assembly 240 is structured topresent an indication that the actual component characteristic is eitheracceptable or not acceptable. For example, the indication may be animage of a green checkmark if the actual component characteristic isacceptable, or the indication may be an image of a red “X” if the actualcomponent characteristic is not acceptable. As another example, theindication may include an image of an envelope showing an acceptablecomponent characteristic as well as an image representing the actualcomponent characteristic, e.g. a curve representing the actual componentcharacteristic over a period of time. If the image representing theactual component characteristic is disposed within the envelope, theactual component characteristic is acceptable, or, if the imagerepresenting the actual component characteristic, or a portion thereof,is disposed outside the envelope, the actual component characteristic isnot acceptable.

Further, the output assembly 240, in an exemplary embodiment, includes acommunication assembly 260 or electronic communication between anysub-assemblies. The communication assembly 260 is structured tocommunicate the output signal to a remote location. The communicationassembly 260 is further structured to communicate raw data or any otherstored information to a remote location. The communication assembly 260may communicate the signal via wired constructs, such as, but notlimited to, fiber optics, Ethernet cables, shielded cables, CAN-BUScommunication system, or wireless constructs, such as, but not limitedto, Near Field Communications (NFS), blue tooth connections, WiFiconnections, Radio Frequency identifications (RFID), satellitecommunications systems, or radio communication systems.

In an exemplary embodiment, the component monitoring system 200, orelements thereof, are modular and may be selectably coupled to aselected circuit breaker assembly. As used herein, “selectably coupled”means that two components are coupled in a manner that allows for thecomponents to be easily decoupled without damaging the components. Therecord assembly 210, the comparison assembly 230, and the outputassembly 240 are disposed in a modular housing assembly 300. The modularhousing assembly 300 includes a number of sidewalls 302 and a selectablecoupling, such as, but not limited to, a tongue and groove coupling (notshown). The modular housing assembly sidewalls 302 defines an enclosedspace 306. The processing assembly 232 and other elements are disposedwithin the modular housing assembly enclosed space 306. For the sake ofthis description, the modular housing assembly 300 is identified as partof the comparison assembly 230. In this configuration, the modularhousing assembly 300 may be moved between different circuit breakerassemblies 10 or various switchgear assemblies (not shown in thefigure).

In an embodiment wherein the sensor assemblies 220 utilize wiredcommunication, the modular housing assembly 300 includes a number ofcommunication ports 310. Each modular housing assembly communicationport 310 is in electronic communication with the processing assembly232. Further, each modular housing assembly communication port 310 isstructured to be in, and is placed in, electronic communication with asensor assembly 220.

In a specific exemplary embodiment, the component monitoring system 200,as well as the displaced component monitoring system 201, is structuredto evaluate the closing spring 90 so as to determine when the closingspring 90 is worn and/or ready for replacement. In this exemplaryembodiment, and as shown in FIG. 4, the following symbols are used:

L=Distance between the center of cam and the upper spring seat;

d=Distance between the center of cam and the lower spring seat;

ω₀=Initial angle when closing spring fully charged;

ω_(t)=Rotation angle when closing spring releasing energy, and

h=Distance from the center of cam to the closing spring central axis.

For the configuration shown in FIG. 4, the length of charging spring attime t can be calculated as:l _(t)=√{square root over (L ² +d ²−2LD cos(w _(o) +w _(t)))}.The spring force can be calculated as the following according toHooker's rule:F _(t)=(l ₀ −l _(t))K.where K is the stiffness of the spring, and, l₀ is the length of closingspring in the opening condition.The aim of this force h can be calculated as:h _(t) =dL sin(w _(o) +w _(t))/1.Therefore, the moment of the spring force at time t can be calculatedas:M _(t) =h _(t) ×F _(t).

A typical envelope of current and charging time for the first chargingcam 60 is shown in FIG. 5. To match the needed torque for the firstcharging cam 60, the charging motor assembly 30 will output torqueequivalent to the clutch and then transmit to the charging spring.Further, the charging current, i.e. the current to the charging motorassembly 30 will correspond to, i.e. change with, the changing torque.The output torque of charging motor assembly 30 can be calculated as:T _(t) =C _(m) Øl _(t),where C_(m) is the torque coefficient, and Ø is the armature flux.Armature flux is the flux generated when excitation current flowsthrough machine winding. The motor works in the saturation area of theflux-current curve; thus, the change of the excitation currentinfluences the armature flux in a minor degree. Therefore, a hypothesisis raised that Ø is a constant then torque is proportional to motorcurrent.

In an exemplary embodiment, the AC/DC converter 47 is used to power theDC motor 48 by an AC source. Thus, in this embodiment the sensorassembly 220 includes a current sensor 220′ associated with, andstructured to measure, the current in the AC conductor 46. The selectednominal current data for the DC current I_(t) can be obtained byextracting the envelope of the measured AC current at the AC conductor46. The nominal current can be obtained in the normal condition bytesting the current during normal use of the circuit breaker assembly10. Such a test is repeated several times to statistically observe andestablish the nominal current. If there is no apparent fluctuation, thenaverage current envelope after signal processing to get the finalnominal current. (Alternatively, the nominal current can be establishedby the least square method or weighed least square method).

Further, in this exemplary embodiment, the sensor assembly 220 includesa motor output shaft torque sensor 220″ structured to measure motoroutput shaft torque in motor output shaft during the actuation of the DCmotor 48. The torque sensor 220″ is coupled, directly coupled, or fixedto the motor assembly output shaft 50 and is structured to measure thetorque therein during actuation of the charging motor assembly 30.Further, the sensor assembly 220 includes a motor timer 220′″. The motortimer 220′″ is structured to measure the time period that the chargingmotor assembly 30 is active, i.e. in motion. The timer 220′″, in anexemplary embodiment, is structured to detect a current in either the ACconductor 46 or the AC/DC converter 47. The timer 220′″ may be combinedwith the current sensor 220′.

In this embodiment, at least three component characteristics of thecharging motor assembly 30 can be used to determine that a closingspring 90 is worn and/or ready for replacement. These componentcharacteristics of the charging motor assembly 30 include, the chargingtime, the output energy of the charging motor assembly 30, and thecorrelation coefficient, as defined below. Accordingly, the currentsensor 220′ is structured to measure the current in the AC conductor 46as well as the time period the charging motor assembly 30 is actuated.

A selected nominal motor charging time “t_(c),” which is determined byexperimentation, is illustrated as in FIG. 6. FIG. 7 depicts a selectednominal time period of the charging process. As discussed below, if thetime period of the charging process exceeds the selected nominal motorcharging time, it is an indication that the external voltage is lowerthan required. The permitted error of the grid voltage is 7% below to10% above. Then the permitted error of charging time can be determined.That is, for example, the energy stored by the charging spring offersthe total kinetic energy to the whole system and the elastic potentialenergy for opening springs and contact springs. An extreme condition canbe considered that if the closing spring ages with its stiffness below acertain value, the circuit breaker fails to close on command. (It can beeasily seen in the torque curve.) As the stiffness decreases, theclosing time will increase and influence the closing quality. Given anindex indicating the closing quality and its range, the predeterminedlimit can be calculated in theory (or deducted by simulation). Theprinciple of calculating the motor output torque can be extended todifferent types of motor and measurements.

The output energy of motor can be calculated as:E=I ² Rt.Considering the resistance R is a constant, the equivalent chargingenergy E₁ can be determined as:E ₁ =E/R=I ² t.

The equivalent charging energy depicts how much energy the chargingmotor assembly 30 exerts when charging the closing spring 90 otheroperating mechanism components 28. The equivalent charging energy can beused as an indicator to diagnose the working condition of the operatingmechanism 16, especially the stiffness of the closing spring 90. Thatis, as the closing spring 90 ages, the equivalent charging energyrequired to charge the equivalent charging energy changes. That is, forexample, a spring may become less stiff if it remains chargedcontinuously, or, a spring may become stiffer/brittle if in standby andexposed to extreme temperatures and humidity. The former is more likelythan the latter. Accordingly, if the equivalent charging energy exceedsa predetermined limit, the closing spring 90 should be replaced. In thisexemplary embodiment, the energy stored by the charging spring definesthe total kinetic energy available to the operating mechanism 16 and theelastic potential energy for opening springs 92 and contact springs 94.An extreme condition can be considered in that, if the closing spring 90ages with its stiffness below a certain value, the operating mechanism16 fails to close on command, as seen in the torque curve. As thestiffness decreases, the closing time will increase and influence theclosing quality. Given an index indicating the closing quality and itsrange, a predetermined limit can be calculated or determined bysimulation.

The correlation coefficient ρ provides a correlation between chargingcurrent I_(t) and theoretical torque M_(t) as follows:

$\rho = \frac{\sum{( {I_{t} - {\overset{\_}{I}}_{t}} )( {M_{t} - {\overset{\_}{M}}_{t}} )}}{\sqrt{\sum{( {I_{t} - {\overset{\_}{I}}_{t}} )^{2}{\sum( {M_{t} - {\overset{\_}{M}}_{t}} )^{2}}}}}$wherein:

I_(t)=the value of motor current envelope in the given time domain;

Ī_(t)=average of I_(t);

M_(t)=theoretical torque provided by motor; and

M _(t)=average of M_(t).

That is, ρ represents how well the charging process matches with thetheoretical model. Thus, ρ is used as an effective index to diagnosiswhether there are defects in the mechanism, especially the closingspring 90 and the first charging cam 60. This equation, again, followsthe standard format of Equation A after certain transformations.

In an exemplary experiment, the motor current in three different workingconditions and the extracted component characteristics, as describedabove, are shown below. In this exemplary experiment, the workingcondition is the normal condition, i.e., an external voltage of 220V,stiffness and the preload of closing spring is normal, and the clutchsystem is lubricated. The under voltage condition of charging motormeans that the external voltage is 180V, while the other conditionsremain the same. The mechanism anomaly condition means a change in thestiffness and preload in simulation, while the other conditions remainthe same. The comparison of waveform can be found in FIG. 7. As is shownin FIG. 7, the measured current envelope matches well with thetheoretical torque curve, and the charging time t_(c) and chargingenergy E have been extracted and calculated as the reference for thenormal condition. The numerical comparison is shown below.

Mode ρ t_(c)(S) E₁(J/Ω) 1. Normal condition 0.9314 0.097 1.4022 2. Undervoltage of 0.799 0.119 1.4828 charging motor 3. Mechanism anomaly 0.74550.094 0.8134 (simulation)

Accordingly, the comparison indicates that, for the failure mode havingan under voltage of the charging motor assembly 30, the charging timewill be longer while the total output energy is similar to the totaloutput energy calculated by theoretical curve. Whereas, for the failuremode having a mechanism anomaly, the theoretical cam torque curvechanges due to the defect in the mechanism. That is, for the failuremode having a mechanism anomaly, the measured circuit envelope will notmatch well with the theoretical energy curve. Considering such factors,a defect in motor and charging mechanism may be detected as well asprovide additional diagnosis information regarding the operatingmechanism 16.

As shown in FIG. 8, a method of using the embodiment of the componentmonitoring system 200, which is also a displaced component monitoringsystem 201, includes selecting 1000 a circuit breaker assembly operatingmechanism component 28 to monitor, measuring 1002 a circuit breakerassembly operating mechanism actual component characteristic of theselected circuit breaker component 28, comparing 1004 the circuitbreaker assembly operating mechanism actual component characteristic ofthe selected circuit breaker component to selected nominal data of aselected circuit breaker component, providing 1006 an indication ofwhether the actual component characteristic is acceptable when comparedto the selected nominal data, and, if the circuit breaker assemblyoperating mechanism actual component characteristic of a selectedcircuit breaker component is not acceptable when compared to theselected nominal data, then replacing 1010 a selected circuit breakercomponent.

In an exemplary embodiment, wherein the selected nominal data and theactual component characteristic output data are electronic constructs,it is understood that the comparing 1004 the circuit breaker assemblyoperating mechanism actual component characteristic of the selectedcircuit breaker component to selected nominal data of a selected circuitbreaker component is performed by comparing the selected nominal dataand the actual component characteristic output data in a computer.

In an exemplary embodiment, wherein the charging motor assembly 30includes AC and DC components as described above, the measuring 1002 acircuit breaker assembly operating mechanism actual componentcharacteristic of the selected circuit breaker component 28 includesmeasuring 1020 at least one of the time period of the actuation of theDC motor, the charging motor assembly output energy, or the motor outputshaft torque.

In an exemplary embodiment wherein the record assembly 210 includes datarepresenting a selected nominal correlation coefficient of a selectedcircuit breaker component, the comparing 1004 the circuit breakerassembly operating mechanism actual component characteristic of theselected circuit breaker component to selected nominal data of aselected circuit breaker component, and providing 1006 an indication ofwhether the actual component characteristic is acceptable when comparedto the selected nominal data, and includes; determining 1030 an actualcorrelation coefficient for a selected circuit breaker component bycomparing a number of characteristics of the selected circuit breakercomponent, comparing 1032 the actual correlation coefficient to theselected nominal correlation coefficient, and providing 1040 anindication of whether the comparison of the actual correlationcoefficient to the selected nominal correlation coefficient is within aselected range or outside a selected range. Further, in an exemplaryembodiment wherein the charging motor assembly 30 is as described above,the determining 1030 an actual correlation coefficient for a selectedcircuit breaker component by comparing 1036 a number of characteristicsof the selected circuit breaker component includes comparing the currentsensor output data and the motor output shaft torque sensor output dataaccording to the equation:

$\rho = \frac{\sum{( {I_{t} - {\overset{\_}{I}}_{t}} )( {M_{t} - {\overset{\_}{M}}_{t}} )}}{\sqrt{\sum{( {I_{t} - {\overset{\_}{I}}_{t}} )^{2}{\sum( {M_{t} - {\overset{\_}{M}}_{t}} )^{2}}}}}$

wherein I_(t) is the AC current in the AC conductor during the actuationof the DC motor;

wherein Ī_(t) is the average nominal AC current in the AC conductorduring the actuation of the DC motor;

wherein M_(t) is the motor output shaft torque in the motor output shaft50 during the actuation of the DC motor; and

wherein M _(t) is the average motor output shaft torque in the motoroutput shaft 50 during the actuation of the DC motor.

Further, in an exemplary embodiment wherein the charging motor assembly30 is as described above, the selecting 1000 a circuit breaker assemblyoperating mechanism component 28 to monitor, and, replacing 1010 aselected circuit breaker component includes monitoring 1001 thecharacteristics of the charging motor assembly 30, and, replacing 1012the closing, first spring 90.

In another exemplary embodiment, the component monitoring system 200, aswell as the displaced component monitoring system 201, is structured toevaluate the forces acting upon a latch member 44 so as to determinewhether the contact spring 94 needs replaced.

The operating mechanism 16 discussed above includes two latch members44; a close latch member 170 and a trip latch member 172. The closelatch member 170 operatively engages the close latch D-shaft 126 in themanner discussed above. The trip latch member 172 operatively engagesthe trip latch D-shaft 124 in the manner discussed above. Thus, when themovable contact assembly 20 is in the second position, force from thecontact spring(s) 94 (or other springs 34, in general) acts through thevarious operating mechanism components 28 on, in an exemplaryembodiment, trip latch member 172. That is, as an example, the followingdescription shall focus on the relationship between the contact spring94 and the trip latch member 172. It is understood that other operatingmechanism components 28 may be monitored to determine that status, i.e.health, of other springs 34.

In an exemplary embodiment, the trip latch member 172 is a monitoringlatch assembly 174. That is, in this exemplary embodiment, themonitoring latch assembly 174 includes a latch member 176 and a sensorassembly 178, as shown in FIGS. 9 and 10. The latch member 176 includesa body 180 defining a pocket 182. The latch member body 180 is agenerally planar body including a latching first end 184 and a couplingsecond end 186. The latch member body second end 186 includes a latchingsurface 188. In an exemplary embodiment, the latch member body secondend latching surface 188 is disposed on the thinner lateral surfacebetween the wide generally planar surfaces of the generally planar latchmember body 180. The latch member body pocket 182 is disposed adjacentthe latch member body second end latching surface 188.

In an exemplary embodiment, the latch member body pocket 182 is sizedand shaped to generally correspond to the sensor assembly 178, discussedbelow. Thus, in an exemplary embodiment, the latch member body pocket182 includes a generally planar first surface 190 and a generally planarsecond surface 192. The latch member body pocket first surface andsecond surface 190, 192 are generally parallel.

As shown in FIGS. 9-11, and in an exemplary embodiment, the sensorassembly 178 includes a disk-like body 194, which is a generally planarbody. That is, the sensor assembly body 194 includes a generally planarfirst surface 196 and a generally planar second surface 198. When thesensor assembly body 194 is disposed in the latch member body pocket182, the sensor assembly body first surface 196 is coupled, directlycoupled, or engagingly coupled to the latch member body pocket firstsurface 190. Similarly, when sensor assembly body 194 is disposed in thelatch member body pocket 182, the sensor assembly body second surface198 is coupled, directly coupled, or engagingly coupled to the latchmember body pocket second surface 192. In an exemplary embodiment, thesensor assembly 178 is structured to measure at least one of a staticpressure or a deformation.

As noted above, in this exemplary embodiment, the component monitoringsystem 200, as well as the displaced component monitoring system 201, isstructured to evaluate the forces acting upon a latch member 44 so as todetermine whether the springs 34, including but not limited to closespring 90, open spring 92, and/or contact spring 94, needs replaced.Thus, in this embodiment, the record assembly 210 includes a desiredrange for the force acting upon the latch member body 180. That is, inthe configuration described above, the operating mechanism components 28generate a number of forces and moments as shown in FIG. 2A. Theseforces and moments include:

F1—The force generated by the contact spring 94;

F2—The force generated by the opening spring 92;

F3—The force acting on the lay shaft casting link member 76 by the firstlink member 74;

F4—The force acting on the first charging cam 60 by main roller 122;

F5—The force acting on the lay shaft casting link member 76 by the mainlink coupler member 77;

F6—The force acting on the trip latch member 172 by the main link member78,

F7—The force acting on the trip latch member 172 by trip latch D-shaft124;

M1—The moment about rocker link shaft 54;

M2—The moment about lay shaft 56; and

M3—The moment about trip latch shaft 59.

Knowing the characteristics, e.g. geometries, materials, positions, etc.of the various operating mechanism components 28, the various forces andmoments above may be calculated. Moreover, as shown in FIGS. 12 and 13,the operating mechanism 16 may be tested so as to establish arelationship (1) between the opening speed of the movable contactassembly 20 and the contact spring 94 force (F1), and, (2) the latchforce (F7) and the contact spring 94. Moreover, an acceptable range forthe opening speed of the movable contact assembly 20, the contact spring94 force (F1), and, (2) the latch force (F7) can be established. Thatis, these values can be initially calculated in a theoretical model.Given the parameters of geometry and material, the transmission ratioand equivalent mass can be determined approximately. Then, themechanical characteristics including opening and closing time, and theforce in the structure can be determined. Applying the simulation methodis used to double check the accuracy of established model. Finally,experiments verify the ideal model and then, by comparison, determinethe threshold of each physical quantity in a certain margin. Forexample, the latch force is calculated by assuming a rotationalequilibrium. In that case, the IM of latch with respect to a rotatingbearing (not shown) is zero (0). Since the latch force is measured bythe sensor, the interaction force added to the spring 94 can then bedetermined given a geometric measurement.

Accordingly, by measuring the latch force (F7) and comparing that to theselected nominal data for the latch force (F7), the need to replace thecontact spring 94 may be determined.

In another exemplary embodiment, the component monitoring system 200, ordisplaced component monitoring system 201, includes a number ofvibration sensor assemblies 320 as well as other sensor assemblies 220.In this embodiment, the component monitoring system 200 includes arecord assembly 210 a comparison assembly 230, and an output assembly240 which operate as discussed above. That is, for example, thevibration sensor assemblies 320 as well as other sensor assemblies 220are in electronic communication with the comparison assembly 230, asdiscussed above.

As used herein, a “vibration sensor assembly” is a sensor assemblystructured to detect vibrations or acceleration in a component, anassembly, a group of components or assemblies, a substantial portion ofthe circuit breaker assembly 10, or the entire circuit breaker assembly10. A vibration sensor assembly 320 is structured to detect vibrationsand it is understood that vibrations may affect more than one component.Hereinafter, an exemplary vibration sensor assembly 320 will bediscussed in relation to, i.e. is structured to detect vibrations in, asubstantial portion of the circuit breaker assembly 10. It is understoodthat this is merely the example used herein and is not limiting. Avibration sensor assembly 320 includes, but is not limited to,accelerometers. It is further understood that in an exemplaryembodiment, the vibration sensor assembly 320 is structured to measurevibration data relative to time; that is, a vibration sensor assembly320 includes a chronometer. The other sensor assemblies 220 used in thisembodiment are structured to detect a gap voltage and a trip coilcurrent. In an exemplary embodiment, the gap voltage sensor assembly 220and a trip coil current sensor assembly 220 also include a chronometer.It is understood the time keeping function may be performed by otherelements of the component monitoring system 200 such as, but not limitedto, the record assembly 210.

In an exemplary embodiment, a number of vibration sensor assemblies 320are coupled, directly coupled, removably coupled or fixed to the circuitbreaker assembly housing assembly 12. The vibration sensor assemblies320 are structured to detect problems with a number of circuit breakerassembly 10 components and as such are, in an exemplary embodiment, partof a displaced component monitoring systems 201. That is, as notedabove, the operating mechanism 16 includes a number of components 28.Some of the operating mechanism components 28 are discussed above. It isfurther noted that the operating mechanism components 28 further includea charging pawl and gear teeth, as well as lubrication (none shown).That is, as used herein, the lubrication used in conjunction with theoperating mechanism 16 is an operating mechanism component 28. In thedisclosed exemplary embodiment, the vibration sensor assembly 320 isstructured to detect problems with the charging pawl, gear teeth,lubrication, the charging motor assembly 30, and selected cam members32. Further, in an exemplary embodiment, as shown, there are threevibration sensor assemblies 320, 320′, 320″ (shown schematically) thatare spaced from each other, i.e. coupled, directly coupled, or fixed todifferent areas of the circuit breaker assembly 10. Further, in anexemplary embodiment, each vibration sensor assemblies 320, 320′, 320″is structured to measure vibrations primarily in one direction (as shownin FIG. 1 by the arrow associated with each sensor) corresponding to anaxis of a Cartesian coordinate system. Further, in this configuration,data from the three vibration sensor assemblies 320, 320′, 320″ may becompared to each other.

Vibrations of any component, assembly, or in this exemplary embodiment,a substantial portion of the circuit breaker assembly 10, are, as usedherein, an “actual component characteristic” (discussed above). As withthe sensor assembly 220 described above, a vibration sensor assembly 320includes, or is structured to be coupled to and in electroniccommunication with, a power source (not shown). Further, a vibrationsensor assembly 320 is further structured to transmit output datarepresenting the circuit breaker component's actual componentcharacteristic which is identified herein as “actual componentcharacteristic output data” (discussed above). As before, and in anexemplary embodiment, the actual component characteristic output datasignal has characteristics of between about 0-10V DC, between about 4-20mA and between about 100-1000 Hz, or, digital signal output.

Thus, as is known, elements of the circuit breaker assembly 10, such as,but not limited to the operating mechanism 16 and the movable contactassembly 20, move between known configurations and positions during theoperation of the circuit breaker assembly 10. The configurations andpositions include the first and second positions noted above as well aspositions and configurations associated with charging the closing spring90. By way of non-limiting example, a circuit breaker assembly 10 maymove through a sequence such as charge-close-charge-open-close-openwherein “charging” relates to the closing spring 90 and “open” and“close” relate to the position of the operating mechanism 16 and themovable contact assembly 20.

In this exemplary embodiment, the record assembly 210, and in anexemplary embodiment the database module 212, includes data representingselected nominal data includes “model selected nominal data.” As usedherein, “model selected nominal data” is data determined via testing ofa “masterpiece circuit breaker.” As used herein, a “masterpiece circuitbreaker” is a circuit breaker assembly that is maintained in anoperational and like new condition. The method of vibration baseddiagnosis and prognosis is initially performed on a masterpiece circuitbreaker and used to generate the model selected nominal data. The modelselected nominal data includes data representing the vibrationsassociated with a masterpiece circuit breaker assembly 10 as thecomponents move into the various positions and during operations suchas, but not limited to, charging the closing spring 90. The same, or asubstantially similar analysis is then performed on an in use circuitbreaker assembly 10 to generate actual component characteristic outputdata and then to calculate calculated component characteristics. Themethod for vibration based diagnosis and prognosis is shown in FIG. 15.

Generally, the method includes performing signal segmentation 2000,performing feature extraction 2002, performing diagnosis and prognosis2004, and providing actionable suggestions 2006. The steps shown on theleft are the primary steps with the sub-steps of each shown to theright.

In an exemplary embodiment, the comparison assembly 230 is structured toinitially performing signal segmentation 2000 on the actual componentcharacteristic output data thereby creating signal data segments. Thatis, the actual component characteristic output data measured on themasterpiece circuit breaker is an electronic construct such as, but notlimited to, a signal. Further, the signal includes data representingtime. Thus, the signal, i.e. the signal is capable of being “segmented,”i.e. broken into distinct periods of time. Thus, the model selectednominal data includes “segmented signal data.” That is, as used herein,“segmented signal data” means a number of portions of data measured overa period of time. Further, each portion of data for a specific period oftime is, as used herein, a “data segment.” Thus, “segmented signal data”includes a number of “data segments.” In an exemplary embodiment, theidentified data segments are associated with each separate phase of thecharge-close-charge-open-close-open sequence discussed above. Further,each segment includes time component.

As shown in FIG. 16, the comparison assembly 230 is structured toperform a signal segmentation including acquiring actual componentcharacteristic output data. This process includes acquiring the actualcomponent characteristic output data 2020, performing a Hilberttransformation to establish an envelope 2022 and establishing time foreach local minimum vibration 2024, which indicates the start of a newmeasure period. To avoid capturing zero point as the local minimum, itis better to extract the envelope of original signal. The envelope canbe calculated from the analytic signal by Hilbert transform of originalsignal. In FIG. 16, analytic signal u(t) is obtained through Hilberttransform of original signal g(t), which is a complex-valued functionthat has no negative frequency components. The envelop of analyticsignal is the sum of the squares of real part and imaginary part.Further, FIG. 16 is a detailed explanation of performing signalsegmentation 2000 (FIG. 15). That is, at “take t sequentially, t=t+1”,the sensors record the local maximum on the envelope of u(t). Ifu(t)<k*mean value of previous n, where k is a pre-set scaling parameterto the mean value, and u(t) is larger than the basic amplitude, which isalso a pre-set parameter, then the current t is a point forsegmentation. The step of u(t)>basic amplitude is the criteria todiscard the dummy segment points.

It is understood that when this step is performed on a masterpiececircuit breaker, the comparison assembly 230 establishes the “segments,”discussed above. Further, in an exemplary embodiment, the comparisonassembly 230 is structured to discard dummy segment points 2026 (FIG.15). Within each segment, when performed on a masterpiece circuitbreaker, the comparison assembly 230 is structured to perform featureextraction 2002. The extracted features include a total energycharacteristic, a segment mean energy attribute, a segment durationattribute, and a time domain correlation attribute. The attributes areestablished according to the following:

Features Meaning Equation E_(total) Total energy in each E_(total) =Σ_(i =) ₁ ^(N) |u_(i)|² segment Ē Segment mean energy$\overset{\_}{E} = {\frac{1}{N}{\sum_{i = 1}^{N}{u_{i}}^{2}}}$ TSegment duration T_(n) = t_(start point of n +) ₁− t_(start point of n)C_(t) Time domain correlation$C_{t} = {\frac{1}{N}{\sum_{i = 1}^{N}{( {u_{i} - \overset{\_}{u}} )( {u_{i}^{standard} - {\overset{\_}{u}}^{standard}} )}}}$

Each segment of vibration corresponds to a major collision in mechanism,and the features extracted from each segment can also represent theproperty of collision. E_(total) presents the total energy in eachsegment. E_(total) is related to the collision intensity and the timeduration. Ē is the average energy in each segment, which is only relatedto the collision intensity. T is the segment duration, which representshow long a collision lasts until the next collision happens. C_(t) is acorrelation number between the measured signal and the standard signalin each segment. C_(t) represents the similarity between the measuredsignal and the signal in a “healthy” circuit breaker.

It is understood that the total energy attribute, the segment meanenergy attribute, the segment duration attribute, and the time domaincorrelation attribute are defined as a range or a limit selected by theuser. That is, the selected range or limit based upon the total energyattribute, the segment mean energy attribute, the segment durationattribute, and the time domain correlation attribute are selected as themodel selected nominal data. Further, each of the total energyattribute, segment mean energy attribute, segment duration attribute,and time domain correlation attribute are calculated by methods such as,but not limited to, Fast Fourier transform (FFT), Short-time Fouriertransform (STFT), Dynamic Time Warping (DTW) data.

Exemplary model selected nominal data for the vibrations associated witha masterpiece circuit breaker during a closing operation are shown inFIG. 17. In an exemplary embodiment, the model selected nominal datafurther includes data representing the gap voltage, trip coil current,the displacement signal associated with the electrode of Phase A, thedisplacement signal associated with the electrode of Phase B, and thedisplacement signal associated with the electrode of Phase C,hereinafter “Displacement A,” “Displacement B,” and “Displacement C,”respectively. The gap voltage is the voltage between the upper and lowerelectrodes, which represents whether the circuit breaker is in an openor close position. The displacement is for the lower electrode withregards to its closed position, and the annotation A, B, C are for threephases.

As shown in FIG. 17, the three time segments are associated withexemplary physical processes and identified as t1, t2, and t3, as wellas t3′, t3″, etc. as the spring oscillates. The first segment, t1, isassociated with the cam 32 and roller 120 impact; the second segment,t2, is associated with the collision (and reduction of velocity to zero)of the of the contact assemblies 20, 22; and, segment t3 is associatedwith the oscillation of the one or more spring 34. Alternatively, inanother graph (not shown) time segments t1, t2, and t3 may be associatedwith different exemplary physical processes. That is, t1 may beassociated with the end of the over travel; t2 may be associated withdamper (not shown) impact, and t3 may be associated with the end on theopening operation.

During operation of the circuit breaker assembly 10, the vibrationsensor assemblies 320, as well as other sensor assemblies 220 notedabove, are used in the same process or method to generate actualcomponent characteristics that is compared to the model selected nominaldata. That is, the comparison assembly 230 is structured to record theactual component characteristic output data and then to calculatecalculated component characteristics. The calculated componentcharacteristics, which are also actual component characteristics, arecompared to the model selected nominal data. In this embodiment, thecomparison assembly 230 is structured to compare the actual componentcharacteristics, i.e. the calculated component characteristics, to themodel selected nominal data. As named herein, the calculated componentcharacteristics shall be identified as the total energy characteristic,the segment mean energy characteristic, the segment durationcharacteristic, and the time domain correlation characteristic,discussed below. The “characteristics” correspond to the “attributes”discussed above. That is, the “attributes” are the actual/calculatedcomponent characteristics for a masterpiece circuit breaker and the“characteristics” are the actual/calculated component characteristicsfor a circuit breaker assembly 10 that is in use.

As stated above, the comparison assembly 230 is structured to comparethe calculated component characteristics to the model selected nominaldata. That is, the comparison assembly 230 is structured to compare,within each measured period and segmented signal data segment, the totalenergy characteristic to the total energy attribute, the segment meanenergy characteristic to the segment mean energy attribute, the segmentduration characteristic to the segment duration attribute, and the timedomain correlation characteristic to the time domain correlationattribute.

In this embodiment, Equation A (above) may be expressed as:y _(i)=β₁ f ₁(t _(i))+β₂ f ₂(t _(i))+β₃ f ₃(t _(i))+ . . . +β_(k) f_(k)(t _(i))+ . . . +ε_(i). Or,y _(i)=β₁ f ₁(t ₁ ,t ₂ ,t ₃ , . . . t _(n))+β₂ f ₂(t ₁ ,t ₂ ,t ₃ , . . .t _(n))+ . . . +ε_(i). Or,y _(i)=β₁ f′ ₁(t ₁ ,t ₂ ,t ₃ , . . . t _(n))+β₂ f ₂(t ₁ ,t ₂ ,t ₃ , . .. t _(n))+ . . . ε_(i). Or,y _(i)=β₁ f ₁(x ₁ _(i) ,x ₂ _(i) , . . . )+ . . . +β_(k) f _(k)(x ₁ _(i),x ₂ _(i) , . . . )+ . . . +εi; Or,In general format:y=Tβ+ε or y=Xβ+ε wherein:

y=a form containing actual component characteristic output dataε(y₁, y₂,. . . , y_(n)) size (n×1);

T=a form assigning relation between time function and actual componentcharacteristic output dataε(f₁(t_(i)), f₂(t_(i)), . . . , f_(k)(t_(i)));

X=a form assigning relation between independent variables and actualcomponent characteristic output dataε(f₁(x₁), f₂(x₂), . . . ,f_(k)(x_(k)));

β=a form with k parameters forming model equation=[β₁β₂ . . . β_(k)]^(T)and k=total number of characteristic output parameters for which thedata is collected; and

ε˜N(O, σ²)=independent and identically distributed random variable(iid)ε(ε₁, ε₂, ε₃, . . . , ε_(n)).

A visual representation of a comparison of the calculated componentcharacteristics to the model selected nominal data for both a first andsecond sensor assembly 320, 320′ is shown in FIGS. 18A-18B (signal fromthird sensor assembly 320″ is not shown). Further, as shown, thechronological position (on the figure) of a calculated componentcharacteristic is associated with a particular operating mechanismcomponents 28. Thus, when any calculated component characteristic isunacceptable relative to the corresponding attribute at a specificchronological position, the unacceptable calculated componentcharacteristic indicates an associated operating mechanism component 28needs attention. That is, the vibrations that occur during a specificoperation, e.g. charging the closing spring 90, are known to happen in aspecific chronological order.

If a calculated component characteristic for a vibration at a specifictime in the sequence charging the closing spring 90 is unacceptable, thecomparison assembly 230 is structured to identify an operating mechanismcomponent 28 associated with that vibration, i.e. the vibration at aspecific time. For example, as shown in FIG. 19, a vibration of acertain magnitude at about 0.16 seconds is associated with unacceptablegear friction. Thus, the comparison assembly 230 is structured toassociate each data segment with a selected component of the circuitbreaker assembly 10.

If any calculated component characteristic is unacceptable relative tothe corresponding attribute, the comparison assembly 230 is structuredto suggest a corrective action and/or identify a potential problem. Itis understood that such suggestions are provided on the output assembly240. Further it is noted that the Fourier transform is, in an exemplaryembodiment, to find outlier data which causes extra frequencycomponents.

The embodiment utilizing a number of vibration sensor assemblies 320 isalso structured to determine the displacement of the contact assemblies20, 22 during opening and closing operations. As used herein,“displacement of the contact assemblies” 20, 22 includes at least twocharacteristics of the movable contact 20; position and velocity.Further, the position of the movable contact 20 relative to thestationary contact 22 is a characteristic identified as “separation,”i.e. the distance between the contact assemblies 20, 22.

That is, in this embodiment, the “actual component characteristic outputdata” (discussed above) is used to estimate the displacement of thecontact assemblies 20, 22. Broadly, the model for estimating a contactdisplacement curve from actual vibration output data is shown in FIG.20. Further, for a closing operation, as represented in FIG. 17, theacceleration of movable contact 20 during segment t1 is assumed to beconstant due to the bias of closing spring 90 and contact spring 94.During an opening operation, the acceleration of movable contact 20during segment t1 is assumed to be constant due to the bias of openingspring 92 and contact spring 94. During segments t2 and t3 of a closingoperation, acceleration is negative due to the dampening effect of adamper (not shown). Thus, given the model shown in FIG. 20, correlationanalysis is used to find the relationship between approximated constantacceleration and vibration data. In an exemplary embodiment,acceleration is estimated from a linear relation to the vibration energyin each segment during which the movable contact 20 is moving. This is,in an exemplary embodiment, represented by the equation:α=kE

Where α is the (approximated) acceleration to be estimated, E is thevibration energy in that segment, and k is the correlation coefficientbetween energy and acceleration, and E is derived by the square sum ofvibration signal as follows;E=αΣv(t)².

The coefficient α is equivalent to the mass of the movable contactassembly 20 and, in an exemplary embodiment, is measured in kilograms.The correlation coefficient k is determined by experimentation on amasterpiece circuit breaker, as follows:

-   -   1. Setting a masterpiece circuit breaker in normal condition.        Install vibration sensor(s) at a selected, fixed location.    -   2. Operating the circuit breaker to open and close. Using the        circuit breaker displacement and velocity measurement        instruments to record the displacement and velocity of the        movable contact assembly 20.    -   3. Calculate the acceleration curve from the measured velocity,        and compare the acceleration curve to the energy curve measured        from vibration.    -   4. Select a point with same interval between maximum and minimum        of velocity curve (t), obtain the corresponding points on energy        curve, and use minimum square error criteria to calculate the        coefficient k between (t) and (t).

It is noted that correlation coefficient k is numeral based upon anexemplary relationship between α and E, as determined by experiment on amasterpiece circuit breaker. Correlation coefficient k is not limited tothe linear relationship between α and E. The relationship is, inexemplary embodiments, α˜√{square root over (E)} or α˜k₁E+k₂E²+ . . . .

The acceleration is used to determine a displacement estimationaccording to the equation:D(t)=∫_(o) ^(t)∫_(o) ^(y)α(x)dxdy

The method discussed above is then used to create a “ClosingDisplacement Characteristic.” As used herein, a “Closing DisplacementCharacteristic” means the displacement of electrode when circuit breakercloses characterized by the closing velocity, the closing time, andselected parameters derived from displacement and time, such as, but notlimited to, overshoot, rebound, and instantaneous velocity at closingpoint. For example, FIG. 21 shows a displacement estimation determinedas described above. That data is then used to generate the ClosingDisplacement Characteristic as shown in FIG. 22.

While specific embodiments of the invention have been described indetail, it will be appreciated by those skilled in the art that variousmodifications and alternatives to those details could be developed inlight of the overall teachings of the disclosure. Accordingly, theparticular arrangements disclosed are meant to be illustrative only andnot limiting as to the scope of invention which is to be given the fullbreadth of the claims appended and any and all equivalents thereof.

What is claimed is:
 1. A component monitoring system structured tomonitor operating mechanism component characteristics of a circuitbreaker assembly, said circuit breaker assembly including an operatingmechanism, said operating mechanism including a charging motor assembly,a first charging cam, a closing first spring, and a first spring camfollower, said charging motor assembly including a rotating outputshaft, said first charging cam fixed to said motor assembly rotatingoutput shaft, said first spring cam follower coupled to said closingfirst spring, said first charging cam operatively engaging said firstspring cam follower, whereby rotation of said first charging camcompresses said closing first spring, said component monitoring systemcomprising: a record assembly including selected nominal data for aselected circuit breaker component; at least one sensor assemblystructured to measure a number of actual component characteristics ofsaid selected circuit breaker component and to transmit actual componentcharacteristic output data; a comparison assembly structured to comparesaid sensor assembly actual component characteristic output data to saidselected nominal data and to provide an indication of whether saidsensor assembly actual component characteristic output data isacceptable when compared to the selected nominal data; said at least onesensor assembly in electronic communication with said comparisonassembly; said record assembly includes data representing a selectednominal correlation coefficient of said selected circuit breakercomponent; said comparison assembly is structured to determine acorrelation coefficient for said selected circuit breaker component bycomparing a number of characteristics of the selected circuit breakercomponent and nominal data; and said comparison assembly is structuredto compare said correlation coefficient to said selected nominalcorrelation coefficient and to provide an indication of whether saidcomparison of said correlation coefficient to said selected nominalcorrelation coefficient is within a selected range or outside saidselected range.
 2. The component monitoring system of claim 1 whereinsaid data representing said selected nominal correlation coefficient isin the form of an envelope.
 3. The component monitoring system of claim1 wherein said charging motor assembly includes an AC conductor, anAC/DC converter, and a DC motor including an output shaft, said ACconductor coupled to, and in electrical communication with, an AC lineas well as said AC/DC converter, said AC/DC converter coupled to, and inelectrical communication with, said DC motor, wherein current passesthrough said AC conductor and said AC/DC converter during the actuationof said DC motor, and wherein: said record assembly includes datarepresenting at least one of a selected nominal charging time, aselected nominal charging motor assembly output energy, or a selectednominal motor force correlation coefficient of said charging motorassembly; said at least one said sensor assembly includes a currentsensor, a motor assembly rotating output shaft torque sensor, and amotor timer; wherein said current sensor is structured to measure saidAC current in said AC conductor during the actuation of said DC motorand to transmit output data representing said AC current in said ACconductor during the actuation of said DC motor; wherein said motoroutput shaft torque sensor is structured to measure motor output shafttorque in said motor assembly rotating output shaft during the actuationof said DC motor and to transmit output data representing said motoroutput shaft torque in said motor assembly rotating output shaft duringthe actuation of said DC motor; wherein said motor timer is structuredto measure the time period of the actuation of said DC motor and totransmit output data representing said time period of the actuation ofsaid DC motor; wherein said comparison assembly is structured todetermine the charging motor assembly output energy; wherein saidcomparison assembly is structured to determine a motor force correlationcoefficient by comparing said current sensor output data and said motoroutput shaft torque sensor output data; and wherein said comparisonassembly is structured to compare at least one of said selected nominalcharging time relative to the output data representing said time periodof the actuation of said DC motor, said selected nominal charging motorassembly output energy relative to said charging motor assembly outputenergy, or, said selected nominal motor force correlation coefficient tosaid motor force correlation coefficient.
 4. The component monitoringsystem of claim 3 wherein said the charging motor assembly output energyis determined by the equation:E ₁ =E/R=I ² t wherein I is the AC current in said AC conductor duringthe actuation of said DC motor, and, wherein R is a predeterminedconstant.
 5. The component monitoring system of claim 3 wherein saidmotor force correlation coefficient is determined by the equation:$\rho = \frac{\sum{( {I_{t} - {\overset{\_}{I}}_{t}} )( {M_{t} - {\overset{\_}{M}}_{t}} )}}{\sqrt{\sum{( {I_{t} - {\overset{\_}{I}}_{t}} )^{2}{\sum( {M_{t} - {\overset{\_}{M}}_{t}} )^{2}}}}}$wherein It is the AC current in said AC conductor during the actuationof said DC motor; wherein It is the selected nominal AC current in saidAC conductor during the actuation of said DC motor; wherein M_(t) is themotor output shaft torque in said motor assembly rotating output shaftduring the actuation of said DC motor; and wherein M _(t) is the averagemotor output shaft torque in said motor assembly rotating output shaftduring the actuation of said DC motor.
 6. The component monitoringsystem of claim 1 wherein: said record assembly is an electronicconstruct; said comparison assembly is an electronic construct; and saidcomparison assembly is in electronic communication with said recordassembly.
 7. A circuit breaker assembly comprising: a charging motorassembly including a rotating output shaft; a first charging cam; aclosing, first spring; a first spring cam follower; a componentmonitoring system; said first charging cam fixed to said motor assemblyrotating output shaft; said first spring cam follower coupled to saidclosing first spring; said first charging cam operatively engaging saidfirst spring cam follower, whereby rotation of said first charging camcompresses said closing first spring; said component monitoring systemincluding a record assembly, at least one sensor assembly and acomparison assembly; said record assembly including selected nominaldata for a selected circuit breaker component; at least one sensorassembly structured to measure a number of actual componentcharacteristics of said selected circuit breaker component and totransmit actual component characteristic output data; said at least onesaid sensor assembly coupled to at least one of said charging motorassembly, said first charging cam, said closing, first spring, or saidfirst spring cam follower; said at least one said sensor assembly inelectronic communication with said comparison assembly; said comparisonassembly structured to compare said sensor assembly actual componentcharacteristic output data to said selected nominal data and to providean indication of whether said sensor assembly actual componentcharacteristic output data is acceptable when compared to the selectednominal data; said record assembly includes data representing a selectednominal correlation coefficient of said selected circuit breakercomponent; said comparison assembly is structured to determine acorrelation coefficient for said selected circuit breaker component bycomparing a number of characteristics of the selected circuit breakercomponent; and said comparison assembly is structured to compare saidcorrelation coefficient to said selected nominal correlation coefficientand to provide an indication of whether said comparison of saidcorrelation coefficient to said selected nominal correlation coefficientis within a selected range or outside said selected range.
 8. Thecircuit breaker assembly of claim 7 wherein said data representing saida selected nominal correlation coefficient is in the form of anenvelope.
 9. The circuit breaker assembly of claim 7 wherein: saidcharging motor assembly includes an AC conductor, an AC/DC converter,and a DC motor; said AC conductor coupled to, an in electricalcommunication with, an AC line as well as said AC/DC converter; saidAC/DC converter coupled to, and in electrical communication with, saidDC motor; wherein current passes through said AC conductor and saidAC/DC converter during the actuation of said DC motor; wherein saidrecord assembly includes data representing at least one of a selectednominal charging time, a selected nominal charging motor assembly outputenergy, or a selected nominal motor force correlation coefficient ofsaid charging motor assembly; said at least one said sensor assemblyincludes a current sensor, a motor assembly rotating output shaft torquesensor, and a motor timer; wherein said current sensor is structured tomeasure said AC current in said AC conductor during the actuation ofsaid DC motor and to transmit output data representing said AC currentin said AC conductor during the actuation of said DC motor; wherein saidmotor output shaft torque sensor is structured to measure motor outputshaft torque in said motor assembly rotating output shaft during theactuation of said DC motor and to transmit output data representing saidmotor output shaft torque in said motor assembly rotating output shaftduring the actuation of said DC motor; wherein said motor timer isstructured to measure the time period of the actuation of said DC motorand to transmit output data representing said time period of theactuation of said DC motor; wherein said comparison assembly isstructured to determine the charging motor assembly output energy,wherein said comparison assembly is structured to determine a motorforce correlation coefficient by comparing said current sensor outputdata and said motor output shaft torque sensor output data; and whereinsaid comparison assembly is structured to compare at least one of saidselected nominal charging time relative to the output data representingsaid time period of the actuation of said DC motor, said selectednominal charging motor assembly output energy relative to said chargingmotor assembly output energy, or, said selected nominal motor forcecorrelation coefficient to said motor force correlation coefficient. 10.The circuit breaker assembly of claim 9 wherein said the charging motorassembly output energy is determined by the equation:E ₁ =E/R=I ² t wherein I is the AC current in said AC conductor duringthe actuation of said DC motor, and, wherein R is a predeterminedconstant.
 11. The circuit breaker assembly of claim 9 wherein said motorforce correlation coefficient is determined by the equation:$\rho = \frac{\sum{( {I_{t} - {\overset{\_}{I}}_{t}} )( {M_{t} - {\overset{\_}{M}}_{t}} )}}{\sqrt{\sum{( {I_{t} - {\overset{\_}{I}}_{t}} )^{2}{\sum( {M_{t} - {\overset{\_}{M}}_{t}} )^{2}}}}}$wherein I_(t) is the AC current in said AC conductor during theactuation of said DC motor; wherein Ī_(t) is the selected nominal ACcurrent in said AC conductor during the actuation of said DC motor;wherein M_(t) is the motor output shaft torque in said motor assemblyrotating output shaft during the actuation of said DC motor; and whereinM _(t) is the average motor output shaft torque in said motor assemblyrotating output shaft during the actuation of said DC motor.
 12. Thecircuit breaker assembly of claim 7 wherein: said record assembly is anelectronic construct; said comparison assembly is an electronicconstruct; and said comparison assembly is in electronic communicationwith said record assembly.
 13. A method of monitoring circuit breakerassembly operating mechanism component characteristics with a componentmonitoring system, said circuit breaker assembly including a chargingmotor assembly, a first charging cam, a closing, first spring, and afirst spring cam follower, said charging motor assembly including arotating output shaft, said first charging cam fixed to said motorassembly rotating output shaft, said first spring cam follower coupledto said closing first spring, said first charging cam operativelyengaging said first spring cam follower, whereby rotation of said firstcharging cam compresses said closing first spring, said componentmonitoring system including a record assembly, at least one sensorassembly and a comparison assembly, said record assembly includingselected nominal data for a selected circuit breaker component, said atleast one sensor assembly structured to measure a number of actualcomponent characteristics of a selected circuit breaker component and totransmit actual component characteristic output data, said at least onesaid sensor assembly coupled to at least one of said charging motorassembly, said first charging cam, said closing, first spring or saidfirst spring cam follower, said at least one said sensor assembly inelectronic communication with said comparison assembly, said comparisonassembly structured to compare said sensor assembly actual componentcharacteristic output data to said selected nominal data and to providean indication of whether said sensor assembly actual componentcharacteristic output data is acceptable when compared to the selectednominal data and, wherein said charging motor assembly includes an ACconductor, an AC/DC converter, and a DC motor, said AC conductor coupledto, an in electrical communication with, an AC line as well as saidAC/DC converter, said AC/DC converter coupled to, and in electricalcommunication with, said DC motor, wherein current passes through saidAC conductor and said AC/DC converter during the actuation of said DCmotor, said method comprising: selecting a circuit breaker assemblyoperating mechanism component to monitor; measuring a circuit breakerassembly operating mechanism actual component characteristic of saidselected circuit breaker component; comparing said circuit breakerassembly operating mechanism actual component characteristic of saidselected circuit breaker component to selected nominal data of saidselected circuit breaker component; providing an indication of whethersaid circuit breaker assembly operating mechanism actual componentcharacteristic is acceptable when compared to the selected nominal data;if said circuit breaker assembly operating mechanism actual componentcharacteristic of said selected circuit breaker component is notacceptable when compared to the selected nominal data, then replacing aselected circuit breaker component; and wherein measuring a circuitbreaker assembly operating mechanism actual component characteristic ofsaid selected circuit breaker component includes measuring at least oneof the time period of the actuation of said DC motor, the charging motorassembly output energy, or the motor output shaft torque.
 14. The methodof claim 13 wherein, said record assembly includes data representing aselected nominal correlation coefficient of said selected circuitbreaker component, and wherein the comparing said circuit breakerassembly operating mechanism actual component characteristic of saidselected circuit breaker component to selected nominal data of aselected circuit breaker component, and the providing an indication ofwhether said circuit breaker assembly operating mechanism actualcomponent characteristic is acceptable when compared to the selectednominal data includes: determining an actual correlation coefficient forsaid selected circuit breaker component by comparing a number ofcharacteristics of the selected circuit breaker component; comparingsaid actual correlation coefficient to said selected nominal correlationcoefficient; and providing an indication of whether said comparison ofsaid actual correlation coefficient to said selected nominal correlationcoefficient is within a selected range or outside said selected range.15. The method of claim 14 wherein the determining an actual correlationcoefficient for a selected circuit breaker component by comparing anumber of characteristics of the selected circuit breaker componentincludes comparing said current sensor output data and said motor outputshaft torque sensor output data according to the equation:$\rho = \frac{\sum{( {I_{t} - {\overset{\_}{I}}_{t}} )( {M_{t} - {\overset{\_}{M}}_{t}} )}}{\sqrt{\sum{( {I_{t} - {\overset{\_}{I}}_{t}} )^{2}{\sum( {M_{t} - {\overset{\_}{M}}_{t}} )^{2}}}}}$wherein I_(t) is the AC current in said AC conductor during theactuation of said DC motor; wherein Ī_(t) is the selected nominal ACcurrent in said AC conductor during the actuation of said DC motor;wherein M_(t) is the motor output shaft torque in said motor assemblyrotating output shaft during the actuation of said DC motor; and whereinM _(t) is the average motor output shaft torque in aid motor assemblyrotating output shaft during the actuation of said DC motor.
 16. Themethod of claim 13 wherein selecting the circuit breaker assemblyoperating mechanism component to monitor and replacing a selectedcircuit breaker component includes: monitoring the characteristics ofsaid charging motor assembly; and replacing said closing, first spring.